Modular power distribution system and method

ABSTRACT

A modular power distribution system comprises a chassis and a backplane including a power input, and a plurality of module connection locations. A plurality of modules are mounted in the chassis, each module mounted to one of the module connection locations. Each module includes: (i) a circuit protection device; and (ii) a power output connection location. Bus bars connect front power inputs to the backplane.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application claiming priority to U.S.patent application Ser. No. 11/710,851, filed Feb. 26, 2007, issuing asU.S. Pat. No. 7,440,262, which is non-provisional application claimingpriority to provisional application Ser. No. 60/873,620, filed Dec. 6,2006, entitled “Modular Power Distribution Systems and Methods”, thedisclosure of which is incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to a power distribution panel with circuitelement modules.

BACKGROUND OF THE INVENTION

Electrical circuit panels such as power distribution panels typicallyinclude a number of different circuit elements such as fuse holders andfuses, circuit breakers, input and output connectors and alarm signalLED's. For safety and other reasons, the electrical circuits of powerdistribution panels are enclosed within a housing structure. Therefore,the circuit elements listed above have typically been inserted intoholes that have been pre-cut or pre-punched into the housing structure,usually on a front or back panel of the housing structure.

These prior circuit panels are fixed and once the holes are formed inthe housing, the type and arrangement of the components is limited. Inorder to manufacture different fixed circuit panels of the priorsystems, a circuit panel manufacturer would punch out different patternsof holes in the front or back panels of the housing structure in orderto accommodate different arrangements of circuit elements. Significantretooling time and costs are involved for offering different fixedpanels. Assembly of the circuit elements is also difficult when theelements are inserted through holes. One solution is described and shownin U.S. Pat. No. 6,456,203.

In addition, such panels are hardwired between the input and outputconnections, and the fuse and/or breaker locations. In some panels,redundant power connections are provided, controlled by an OR-ing diodeincluding a heat sink. These features can take up significant spacewithin the panel.

There is a continued need for improved power distribution panels.

SUMMARY OF THE INVENTION

A modular power distribution system comprises a chassis and a backplaneincluding a power input, and a plurality of module connection locations.A plurality of modules are mounted in the chassis, each module mountedto one of the module connection locations. Each module includes: (i) acircuit protection device; and (ii) a power output connection location.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front, top, and right side perspective view of oneembodiment of a power distribution panel in accordance with the presentinvention.

FIG. 2 is a rear, top, and left side perspective view of the powerdistribution panel of FIG. 1.

FIG. 3 is a front view of the power distribution panel of FIG. 1.

FIG. 4 is a right side view of the power distribution panel of FIG. 1.

FIG. 5 is an exploded front, top, and right side perspective view of thepower distribution panel of FIG. 1.

FIG. 6 is an exploded front, top, and left side perspective view of thepower distribution panel of FIG. 1.

FIG. 7 is a top view of the power distribution panel of FIG. 1, shownwith a top cover portion removed.

FIG. 8 is a front view of the chassis of the power distribution panel ofFIG. 1, shown without modules.

FIG. 9 is perspective view of a first circuit module.

FIG. 10 is a top view of the first circuit module.

FIG. 11 is a bottom view of the first circuit module.

FIG. 12 is a front view of the first circuit module.

FIG. 13 is a right side view of the first circuit module.

FIG. 14 is an exploded perspective view of the first circuit module.

FIG. 15 is a perspective view of a second circuit module.

FIG. 16 is a top view of the second circuit module.

FIG. 17 is a bottom of the second circuit module.

FIG. 18 is a front view of the second circuit module.

FIG. 19 is a right side view of the second circuit module.

FIG. 20 is an exploded perspective view of the second circuit module.

FIG. 21 is a front, top, and right side perspective view of a secondembodiment of a power distribution panel in accordance with the presentinvention.

FIG. 22 is a rear, top, and left side perspective view of the powerdistribution panel of FIG. 21.

FIG. 23 is a front view of the power distribution panel of FIG. 21.

FIG. 24 is a right side view of the power distribution panel of FIG. 21.

FIG. 25 is an exploded front, top, and right side perspective view ofthe power distribution panel of FIG. 21.

FIG. 26 is an exploded front, top, and left side perspective view of thepower distribution panel of FIG. 21.

FIG. 27 is a top view of the power distribution panel of FIG. 21, shownwith a top cover portion removed.

FIG. 28 is a front view of the chassis of the power distribution panelof FIG. 21, shown without modules.

FIG. 29 is a front, top, and right side perspective view of a thirdembodiment of a power distribution panel in accordance with the presentinvention.

FIG. 30 is a front, bottom, and right side perspective view of the powerdistribution panel of FIG. 29.

FIG. 31 is a front perspective view of a first circuit module of thepower distribution panel of FIG. 21.

FIG. 32 is a rear perspective view of the first circuit module of FIG.31.

FIG. 33 is a front view of the first circuit module of FIG. 31.

FIG. 34 is a side view of the first circuit module of FIG. 31.

FIG. 35 is a top view of the first circuit module of FIG. 31.

FIG. 36 is a bottom view of the first circuit module of FIG. 31.

FIG. 37 is a cross-sectional view of the first circuit module of FIG.31, taken along lines 37-37 of FIG. 35.

FIG. 38 is an enlarged view of a portion of the first circuit module ofFIG. 37, shown partially connected to a backplane connector.

FIG. 39 is an exploded front perspective view of the first circuitmodule of FIG. 31.

FIG. 40 is a front perspective view of a second circuit module of thepower distribution panel of FIG. 21.

FIG. 41 is a rear perspective view of the second circuit module of FIG.40.

FIG. 42 is a front view of the second circuit module of FIG. 40.

FIG. 43 is a side view of the second circuit module of FIG. 40.

FIG. 44 is a top view of the second circuit module of FIG. 40.

FIG. 45 is a bottom view of the second circuit module of FIG. 40.

FIG. 46 is a cross-sectional side view of the second circuit module ofFIG. 40, taken along lines 46-46 of FIG. 44.

FIG. 47 is an enlarged view of a portion of the second circuit module ofFIG. 46, shown partially connected to a backplane connector.

FIG. 48 is an exploded perspective view of the second circuit module ofFIG. 40.

FIG. 49 is a flow chart relating to the voltage disconnect monitor.

FIG. 50 shows greater detail of a front of a power distribution panelincluding two of the first circuit modules of FIG. 31, including thelabel configurations.

FIG. 51 shows greater detail of a front of the power distribution panelof FIG. 21, including the label configurations.

FIG. 52 shows in greater detail a front of another power distributionpanel including four of the second circuit modules of FIG. 40, includingthe labeling configurations.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1-7, a power distribution system or panel 10 isshown. Power distribution system 10 is a modular design including apanel construction having a chassis 12 and at least one removablecircuit module 14. In the illustrated embodiment, one first circuitmodule 16, and two second circuit modules 18 are shown. First circuitmodule 16 is positioned in a left side of chassis 12 wherein the firstcircuit module 16 is of a first design. Two second circuit modules 18are also shown positioned in a right side of chassis 12 wherein secondcircuit modules 18 are of a different design from first circuit module16.

Each circuit module 14 includes circuit distribution components. In thepreferred embodiment, the circuit distribution components include acircuit protection device, such as a fuse or a breaker, and a poweroutput arrangement 60. System 10 includes a power input arrangement 50wherein the circuit protection devices within the modules 14 protect thecircuit between the power input arrangement 50 and the power outputarrangement 60.

Referring also to FIG. 8, chassis 12 includes a top 30, a spaced apartbottom 32 and opposite sides 34, 36. Adjacent to sides 34, 36 arebrackets 38 for mounting to a rack, cabinet, or other telecommunicationsequipment. Chassis 12 includes a rear 40. Chassis 12 defines an interior42 having an open front 44. Chassis interior 42 in the illustratedembodiment includes a first module receiving area 46 on a left side ofchassis 12, and a second module receiving area 48 on a right side ofchassis 12. A central area 49 of chassis 12 is provided. In someembodiments, central area 49 can be used for alarming and/or systemmanagement components.

Panel 10 includes power input connectors or terminals 50 connected tointernal bus bars 52. A backplane 54, such as a printed circuit board,is positioned adjacent to rear 40 of chassis 12. Bus bars 52 connectinput connectors 50 to backplane 54. Modules 16, 18 interconnect withbackplane 54 to enable power distribution through modules 16, 18. Eachmodule 16, 18 includes at least one power output connector 60, and acircuit protection device 62, such as a fuse or a breaker.

As shown in FIG. 7, bus bars 52 are generally Z-shaped metallic barsextending from first ends 68 to opposite ends 70. Opposite ends 70define dual contact points 72 which can be mounted with fasteners (notshown) to backplane 54 to electrically interconnect bus bars 52 andbackplane 54. Ends 68 of bus bars 52 are mounted to input terminals 50at input terminal mounts 76 of chassis 12.

Interior 42 of chassis 12 includes side supports 80 and central support82. Side supports 80 and central support 82 include a plurality ofmodule guides 84 which define longitudinal slots for receipt oflongitudinal rails of each of modules 16, 18. Central support 82 definesan interior for receiving an alarm card 92. Alarm card 92 mounts toalarm card connector 93 on backplane 54. Alarm card 92 is optional ifsuch functionality is employed by panel 10.

Each module 16, 18 includes a rear module connector 96. Backplane 54includes a front face 100, and opposite rear face 102. Positioned onfront face 100 are a plurality of mating connectors 104 for electricallyconnecting to the module connectors 96.

Referring now in greater detail to FIGS. 9-14, first circuit module 16is shown. Module 16 includes a frame 200 including a base 202, and afront tray 204 with a front lip 206. A vertical support 208 extends upfrom base 202 and defines a plurality of openings 210, 212 for outputterminal units 220, and fuses 222, respectively. Base 202 also includessides 226 and longitudinal rails 228. A printed circuit board 230connects between module connector 96 and the circuit elements includingoutput terminal units 220 and fuses 222. Fuse holder or block 240 withfuses 222 is held in place by a support tray 241 and a strap 242.

Referring now to FIGS. 15-20, one of the second circuit modules 18 isshown. Second module 18 includes a frame 300 including a base 302, afront tray 304, and a front lip 306. A vertical support 308 defines aplurality of openings 310, 312 for output terminal units 320 and fuses322, respectively. Frame 300 includes sides 326, and longitudinal rails328. A printed circuit board 330 connects between module connector 96and the circuit elements including output terminal units 320 and fuses322.

Modules 16, 18 mount to chassis 12 with fasteners (not shown) throughholes 238, 338 in each module, and holes 66 in supports 80 of chassis12. Front trays 204, 304 are provided for cable management of the poweroutput cables. Front lips 206, 306 also provide a convenient grippingsurface.

Because of the modular design for chassis 12 and modules 16, 18, repairor replacement of parts is facilitated. Should upgrades becomedesirable, new modules can be provided. The modules also allow fordistributed control functions, such as in the case of redundant (dualfeed) applications. The OR-ing diodes or other controllers can belocally placed on each module.

Each module includes the desired circuit protection components. Module16 in the illustrated embodiment is a TPA type fuse. Modules 18 are GMTtype fuses. Other fuse types or breakers can be used.

Referring now to FIGS. 21-52, further embodiments of power distributionsystems or panels similar to panel 10 are shown. In FIGS. 21-28, asimilar panel 410 is shown having a chassis 412, a first circuit module416, and two second circuit modules 418. Alternatively, panel 410 canhold two first circuit modules 416, or four second circuit modules 418.

Chassis 430 includes air flow openings 440 on a top 430, and on a bottom432. Chassis 430 further includes a forward facing ground 442 on top430.

As with panel 10, first circuit module 416 and second circuit modules418 are removable from chassis 430. Module 416 in the illustratedembodiment is a TPA type fuse with four fuses instead of two as noted inpanel 10. Modules 318 are GMT type fuses, each including four fuses,instead of three as noted above for modules 18.

Referring now to FIGS. 26-28, a baffle plate 480 is shown mounted to abottom 432 of chassis 430. Baffle plate 480 is spaced from bottom 432 byspacers 481 so as to allow airflow communication with openings 440 inbottom 432. Baffle plate 480 also functions as an airflow blocker toblock warm air from below chassis 430 from entering into chassis 430,such as from heat emitting equipment mounted below.

Referring now to FIGS. 29 and 30, a further embodiment of a panel 510 isshown. Panel 510 includes the same chassis 430 as for panel 410, andfour second modules 418, two on each side. Panel 510 also is shownincluding baffle plate 480. Baffle plate 480 also includes a front lip482 positioned in an upward direction relative to a remainder of baffleplate 480. Front lip 482 and the rest of baffle plate 480 can alsofunction as a cable tray for holding cables extending to and from panel510, or for cables extending between equipment on either side of panel510.

Referring now to FIGS. 31-39, first module 416 is shown in greaterdetail. Module 416 includes a frame 600 including a base 602, and afront tray 604 with front lips 606. Front tray 604 includes perforations607 for use with cable ties. A vertical support 608 extends up from base602 and defines a plurality of openings 610, 612 for output terminalunits 620, and fuses 622, respectively. Base 602 also includes sides 626and longitudinal rails 628. Two printed circuit boards 630, 631 connectbetween module connectors 696 and the circuit elements including outputterminal units 620 and fuses 622. Fuse holder or block 640 with fuses622 is held in place by a support tray 641 and a strap 642. Variousopenings 646 are provided in base 602 and tray 641 to assist withventilation.

Referring now to FIGS. 40-48, second module 418 includes a frame 700including a base 702, and a front tray 704 with front lips 706. Similarperforations 707 are provided for use as cable ties in front tray 704. Avertical support 708 defines a plurality of openings 710, 712 for outputterminal units 720 and fuses 722 respectively. Frame 700 includes sides726, and longitudinal rails 728. A printed circuit board 730 connectsbetween module connector 696 and the circuit elements including outputterminal units 720 and fuses 722. Various openings 746 are provided inbase 702 to assist with ventilation.

Referring now to FIGS. 38, 47, and 49, a voltage disconnect feature isillustrated. One issue that can arise with removing of a module duringoperation is that arcing may occur between the connectors 696 of themodules, and the connectors 104 of the backplane. A voltage disconnectsystem 800 is provided to turn off the power to the module prior toremoval of the module in order to prevent arcing. A selected pin 808among pins 806 of connector 696 is provided with a shortened length. Theshortened pin 808 will disengage first before the power connectionsdisengage. This will provide an interrupt signal that will be receivedby a device, such as a microcontroller or a similar device on themodule, to activate a voltage disconnect mechanism which turns off thecurrent to the load. This will prevent arcing on the connectors andprevent damage from occurring. Furthermore, if the module is notcompletely inserted, the short pin 808 will prevent the voltagedisconnect mechanism from activating and keep the output current turnedoff until the module is fully inserted. A visual indication will bedisplayed if the module is not fully inserted. FIG. 49 illustrates anexample flow chart illustrating the voltage disconnect feature.

Each module 416, 418 includes various visual indicators to indicatesystem conditions. For example, there are provided visual indicationsfor power, low voltage, blown fuse, and excess temperature throughvisual indicators 900.

Power input covers 910, and power output covers 920 can be provided ifdesired.

As shown in FIGS. 50-52, various arrangements for panels 410, 510, 1010are shown using the same chassis 430. Labels 1200, 1210, 1220 can beused to label each module 416, 418 as needed for each arrangement.Labels 1200, 1210, 1220 can be adhesively attached to each module 416,418 as needed.

1. A power distribution system comprising: (a) a chassis including: (i)an open front; (ii) front power input connections; (b) a backplaneincluding: (i) a plurality of power inputs electrically connected to thefront power input connections; (ii) a plurality of module connectionlocations; (c) a module mounted in the chassis to one of the moduleconnection locations, the module including: (i) control circuitry; and(ii) a power output connection.
 2. The power distribution system ofclaim 1, further comprising a bus bar arrangement connecting the frontpower input connections of the chassis to the power inputs of thebackplane.
 3. The power distribution system of claim 2, wherein the busbar arrangement includes a plurality of Z-shaped metal bus barsextending from the front power input connections to the power inputs ofthe backplane, wherein the power inputs of the backplane face toward therear of the chassis.
 4. The power distribution system of claim 1,wherein each of the plurality of module connection locations includes avoltage disconnect feature.
 5. The power distribution system of claim 1,further comprising an alarm connector on the backplane, and an alarmcard mounted in the chassis in the open front.
 6. The power distributionsystem of claim 1, wherein the module further includes a printed circuitboard connected between the power output connection and the moduleconnection location, the printed circuit board including at least aportion of the control circuitry.
 7. The power distribution system ofclaim 1, wherein the module includes a power input connector mateablewith one of the module connection locations of the backplane, whereinthe power input connector includes a plurality of pins, wherein one ofthe pins is shorter than a remainder of the pins.
 8. The powerdistribution system of claim 1, wherein the module further includes avisual indicator.
 9. The power distribution system of claim 8, whereinthe visual indicator is selected from the group comprising: a powerindicator; a low voltage indicator; a blown fuse indicator; and atemperature indicator.
 10. The power distribution system of claim 1,wherein each module includes an OR-ing diode.
 11. The power distributionsystem of claim 1, wherein each module further includes a circuitprotection device.
 12. The power distribution system of claim 11,wherein the circuit protection device of at least one of the modulesincludes a fuse accessible from a front of the module while the moduleis mounted in the chassis.
 13. A power distribution system comprising:(a) a chassis housing including: (i) a top, a bottom, a rear, oppositeoutside panels and inside panels, and an open front arranged forreceiving one or more power distribution modules; (ii) front power inputconnections; (b) a backplane mounted within the chassis housing andincluding: (i) a plurality power inputs; (ii) a plurality of moduleconnection locations; (c) a bus bar arrangement connecting the frontpower input connections to the power inputs of the backplane, the busbar arrangement including a plurality of Z-shaped metal bus barsextending from the front power input connections to the power inputs ofthe backplane.
 14. The power distribution system of claim 13, whereineach of the plurality of module connection locations includes a voltagedisconnect feature.
 15. The power distribution system of claim 13,wherein the backplane includes an alarm card connector.
 16. The powerdistribution system of claim 13, wherein the backplane is adjacent tothe rear of the chassis.
 17. The power distribution system of claim 13,further comprising a baffle plate mounted to the bottom of the chassis.18. The power distribution system of claim 17, wherein the baffle plateis mounted to the bottom by spacers to allow airflow from openings inthe bottom.
 19. The power distribution system of claim 17, wherein thebaffle plate includes a front lip providing cable support.
 20. The powerdistribution system of claim 19, wherein the front lip form at leastpart of a cable tray.
 21. A chassis for a modular power distributionsystem, wherein the power inputs of the backplane face toward the rearof the chassis housing.
 22. A power distribution system comprising: (a)a chassis including: (i) an open front; (ii) front power inputconnections; (b) a backplane including: (i) a plurality power inputselectrically connected to the front power input connections; (ii) aplurality of module connection locations; (iii) an alarm card connector;(c) a plurality of modules mounted in the chassis to the moduleconnection locations, each module including: (i) a printed circuit boardincluding control circuitry; (ii) a circuit protection device; and (iii)a power output connection. (d) an alarm card connected to the alarm cardconnector of the backplane and mounted in the chassis in the open front.